https://iesmasterpublications.com/non-tech-books/general-principles-of-design-drawing-and-safety The Process of applying technical knowledge to generate a new processes or machines or to modify existing things to meet the new requirements of society, people, organisation is termed as ‘design’. While ‘drawing’ is a language of engineers to express their creativity in written form. Once we have developed the design and drawing, one more important thing to be considered is safety in design without which all previous developments will become meaningless. The book “General Principal of Design, Drawing and Safety” has been written to address the need of students appearing for UPSC Engineering Services Exam (ESE).Most of the books on this subject have been written too extensively and with a particular branch of engineering in focus, which makes most of the part of the book irrelevant for the exam. In this book we have tried to cover all the relevant topics pertinent to the exam and have introduced important information’s in boxes to attract special attention and to clarify important concepts. objective questions have been introduced at the end for practice and to discover the extent of students knowledge.

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ESE-2020
Prelims Paper-I
General Principles of
Design, Drawing & Safety

3. First Edition : 2016
Second Edition : 2017
Third Edition : 2018
Fourth Edition : 2019
Typeset at : IES Master Publication, New Delhi-110016
IES MASTER PUBLICATION
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4. PREFACE
Giving life to an engineer’s dream for the betterment of society involves Design, Drawing and Safety. With
the increasing complexities of economy, as well as the ensuing disruption in IT, besides the stringent safety
rules, this inter-disciplinary subject has become quite challenging to comprehend from exam point of view.
Looking at the nature of Engineering Services Examination (ESE), and the level of questions being asked,
the conventional approach of preparing through theory and examples is not enough to serve the purpose. The
revised and updated edition of General Principles of Design, Drawing and Safety attempts to provide
logical reasoning through mathematical analysis, gives a clear insight into the concepts, and paints a
complete picture in front of you. In line with this, the book has been written in a simple and clear manner.
The book is divided into three major parts (i) Engineering Drawing (ii) Engineering Design and (iii) Engineering
Safety. The first part discusses the basic principle of drawing associated with drafting of various points,
object, sketches etc. Next, an overview of basic principles of design, types of design, associated governing
tools and product development. Finally, basic knowledge need for engineering safety is presented. In addition
to the above, UPSC sample papers and questions asked in ESE 2017-2019 are discussed after the completion
of relevant topics. For students to determine their level of preparation, self-practice questions have been
provided at the end of this book. Students may generally not require any additional study, and may be
reasonably confident that all the probable questions and topics are covered in this book.
In their endeavour to give students the best, IES Master has brought about this book in an easy-to-grasp
language that gives in a complete clarity of thought. As a result, what students get is their collective wisdom
that breaks free the constraints of engineering students in appreciating the basics of Design, Drawing and
Safety.
As you flip over the pages of this book, you would come across a slew of diagrams, flow charts, mind maps
and tables. This book is a delight for every ESE aspirant as it communicates, connects, and builds upon
the exam preparedness right up to the standards of the UPSC.
All care has been taken to make the understanding of this subject more clear and interesting. The credit goes
to the entire IES Master team for their continuous support in bringing out this book. All comments and
suggestions for further improvement of the book are welcome and will be appreciated.
Bipin Thakur
IES Master Publication
New Delhi

5. Section Description Page No.
Preface (iii)
Engineering Drawing 01-130
Chapter 1 INTRODUCTION TO ENGINEERING DRAWING 1 – 9
1.1 Introduction .................................................................................................................................. 1
1.2 Drawing Sheets ........................................................................................................................... 1
1.3 Drawing Board ............................................................................................................................ 2
1.4 Scales ........................................................................................................................................... 3
1.5 Mini Drafter .................................................................................................................................. 3
1.6 T-Square ....................................................................................................................................... 3
1.7 Set Square ................................................................................................................................... 3
1.8 Protractor ..................................................................................................................................... 4
1.9 Compass ...................................................................................................................................... 4
1.10 Dividers ......................................................................................................................................... 5
1.11 Drawing Pencil ............................................................................................................................ 5
1.12 French Curves ............................................................................................................................. 5
1.13 Layout of a Drawing Sheet....................................................................................................... 6
Chapter 2 LINES, LETTERING AND DIMENSIONING 10 – 22
2.1 Lines ............................................................................................................................................ 10
2.2 Lettering ..................................................................................................................................... 11
2.3 Dimensioning ............................................................................................................................. 12
2.4 Methods of Dimensioning ....................................................................................................... 13
2.5 Arrangement of Dimensions .................................................................................................. 14
2.6 Dimensioning of Various Objects .......................................................................................... 14
2.7 Symbols and Abbreviations Used in Dimensioning ........................................................... 17
2.8 General Rules of Dimensioning ............................................................................................. 17
Chapter 3 GEOMETRICAL CONSTRUCTIONS 23 – 27
3.1 Introduction ................................................................................................................................ 23
3.2 Basic Geometrical Shapes ..................................................................................................... 23
CONTENTS

6. Contents (v)
Chapter 4 SCALES 28 – 33
4.1 Introduction ................................................................................................................................ 28
4.2 Size of Scale ............................................................................................................................. 28
4.3 Representative Fraction (R.F.) ................................................................................................ 29
4.4 Units of Length and their Conversion .................................................................................. 29
4.5 Types of Scales ........................................................................................................................ 30
Chapter 5 ENGINEERING CURVES 34 – 59
5.1 Introduction ................................................................................................................................ 34
5.2 Conic Sections or Conics ....................................................................................................... 34
5.3 Special Curves .......................................................................................................................... 41
5.4 Plane Curves ............................................................................................................................. 41
5.5 Space Curve .............................................................................................................................. 54
Chapter 6 THEORY OF PROJECTIONS 60 – 75
6.1 Introduction ................................................................................................................................ 60
6.2 Projection Methods .................................................................................................................. 60
Chapter 7 PROJECTIONS OF POINTS 76 – 83
7.1 Introduction ................................................................................................................................ 76
7.2 Locations of a Point ................................................................................................................ 77
7.3 Summary .................................................................................................................................... 81
Chapter 8 PROJECTIONS OF LINES 84– 99
8.1 Introduction ................................................................................................................................ 84
8.2 BIS Conventions for Projection of Lines ............................................................................ 84
8.3 Different Orientation of Lines and their Projections ....................................................... 84
8.4 Traces of a Line ....................................................................................................................... 94
8.5 Auxiliary Plane Projection Method ....................................................................................... 95
Chapter 9 PROJECTION OF PLANES 100 – 106
9.1 Introduction ............................................................................................................................. 100
9.2 Orientation of Planes and their Projections .................................................................... 100
9.3 Suspended Planes ................................................................................................................ 104
Chapter 10 PROJECTIONS OF SOLIDS 107 – 118
10.1 Introduction ............................................................................................................................. 107
10.2 Right Solid ............................................................................................................................... 107
10.3 Frustums and Truncated Solid ............................................................................................ 108
10.4 Orientation of Solid and their Projections ........................................................................ 109

7. (vi) Contents
10.5 Suspended Solids ................................................................................................................... 112
10.6 Section of Solids .................................................................................................................... 113
10.7 Intersection of Surfaces of Solids ...................................................................................... 114
Chapter 11 DEVELOPMENT OF SURFACES 119 – 123
11.1 Introduction .............................................................................................................................. 119
11.2 Methods of Development of Lateral Surfaces ................................................................ 120
Chapter 12 COMPUTER AIDED DESIGN 124 – 130
12.1 Computer Aided Design (CAD) ............................................................................................ 124
12.2 Basic Elements of a CAD System .................................................................................... 124
12.3 Major Benefits of CAD ......................................................................................................... 124
12.4 Major CAD Software Products ........................................................................................... 125
12.5 AutoCAD .................................................................................................................................. 125
Engineering Design 131-228
Chapter 1 INTRODUCTION 131 – 137
1.1 Types of Engineering Design ............................................................................................... 131
1.2 Importance of Engineering Design ..................................................................................... 132
1.3 The Design Process ............................................................................................................. 132
Chapter 2 CONCEPTUAL DESIGN 138 – 147
2.1 Introduction ............................................................................................................................. 138
2.2 Problem Definition ................................................................................................................. 138
2.3 Gather Information................................................................................................................. 141
2.4 Concept Generation ............................................................................................................... 141
2.5 Evaluation Method ................................................................................................................. 147
Chapter 3 EMBODIMENT & DETAIL DESIGN 148 – 151
3.1 Introduction ............................................................................................................................. 148
3.2 Detail Design........................................................................................................................... 150
3.3 Design Reviews ...................................................................................................................... 151
Chapter 4 SYSTEM ENGINEERING AND PRODUCT DEVELOPMENT 152 – 162
4.1 Introduction .............................................................................................................................. 152
4.2 Product Development.............................................................................................................. 153
4.3 What is Robust Design .......................................................................................................... 158

9. Contents (vii)
Chapter 5 PROBLEM-SOLVING TOOLS 163 – 171
5.1 Introduction .............................................................................................................................. 163
5.2 Problem Definition .................................................................................................................. 163
5.3 Cause Finding .......................................................................................................................... 164
5.4 Solution Planning and Implementation ............................................................................... 166
Chapter 6 MISCELLANEOUS 172 – 228
6.1 Stresses and Strains ............................................................................................................. 172
6.2 Shearing Stress ...................................................................................................................... 173
6.3 Normal Strain .......................................................................................................................... 173
6.4 Stress and Strain in Simple Bar ......................................................................................... 173
6.5 Deformation (  ) of Member Under Axial Load ................................................................ 174
6.6 Composite Bars ...................................................................................................................... 175
6.7 Problem Involving Temperature Change ............................................................................ 176
6.8 Poisson’s Ratio ....................................................................................................................... 177
6.9 Some Standard Results of Slopes (  ) and Deflections (  ) ....................................... 177
6.10 Maximum Bending Stress at a Section ............................................................................. 180
6.11 Spring ........................................................................................................................................ 181
6.12 Thick Shell and Thin Shell .................................................................................................... 184
6.13 Foundation ................................................................................................................................ 186
6.14 The Retaining Structure ........................................................................................................ 191
6.15 Coffer Dam ............................................................................................................................... 192
6.16 Trusses ..................................................................................................................................... 193
6.17 Arches ...................................................................................................................................... 194
6.18 Cables ....................................................................................................................................... 194
6.19 Beam ......................................................................................................................................... 195
6.20 Slab ........................................................................................................................................... 195
6.21 Column ...................................................................................................................................... 195
6.22 Plate Girders............................................................................................................................ 195
6.23 Gantry Girders ......................................................................................................................... 196
6.24 Coulomb’s Law of Electrostatics ........................................................................................ 196
6.25 Electric Intensity (E) ............................................................................................................... 197

10. (viii) Contents
6.26 Electric Dipole ......................................................................................................................... 197
6.27 Electric Dipole Moment (P) ................................................................................................... 197
6.28 Electric Flux ............................................................................................................................. 197
6.29 Electric Potential ..................................................................................................................... 197
6.30 Electrical Potential Energy .................................................................................................... 197
6.31 Reactance (X) .......................................................................................................................... 197
6.32 Circuit Elements ...................................................................................................................... 198
6.33 Transformers ........................................................................................................................... 199
6.34 Transformer Losses .............................................................................................................. 199
6.35 Synchronous Motors .............................................................................................................. 200
6.36 Induction Motors ..................................................................................................................... 200
6.37 Shaft .......................................................................................................................................... 200
6.38 Keys........................................................................................................................................... 203
6.39 Splines ...................................................................................................................................... 203
6.40 Types of Welded Joints ........................................................................................................ 204
6.41 Friction Clutches ..................................................................................................................... 204
6.42 Belt Drives ................................................................................................................................ 206
6.43 Bearing...................................................................................................................................... 208
6.44 Governor .................................................................................................................................... 211
6.45 Gear ........................................................................................................................................... 212
6.46 Gyroscope ................................................................................................................................ 214
6.47 Design for X (DFX).................................................................................................................. 214
Engineering Safety 229-324
Chapter 1 ACCIDENT, HAZARD AND HAZARD ANALYSIS 229 – 236
1.1 Safety ........................................................................................................................................ 229
1.2 What is an Accidents ............................................................................................................ 230
1.3 Hazard ....................................................................................................................................... 230
Chapter 2 RISK ANALYSIS AND MANAGEMENT 237 – 241
2.1 Risk Management ................................................................................................................... 237
2.2 Risk Analysis Process and Methods ................................................................................. 239
2.3 Role of ‘IT’ in Health and Safety Management ................................................................. 239

11. Contents (ix)
2.4 Social Dimension of Risk-Contemporary Thinking ........................................................... 240
2.5 Evaluating Risk in Design ..................................................................................................... 240
2.6 Risk Control Measures .......................................................................................................... 240
Chapter 3 HUMAN FACTORS IN SAFETY 241 – 244
3.1 Job Stress ............................................................................................................................... 241
3.2 Occupational Stressors and Workplace Stress Effects ................................................ 241
3.3 Physical Stress Influencing Factors ................................................................................... 242
3.4 Human Operator’s Stress Characteristics ........................................................................ 242
3.5 Worksite Analysis Program for Human Factors .............................................................. 242
Chapter 4 SAFETY MANAGEMENT PRINCIPLES 244 – 251
4.1 Introduction .............................................................................................................................. 244
4.2 Safety Management Principles ............................................................................................ 244
4.3 Responsibilities Non-Safety Managers ............................................................................... 246
4.4 Safety Committees ................................................................................................................. 246
4.5 Improving the Workplace Ergonomics ............................................................................... 247
4.6 Safety Audit ............................................................................................................................. 248
4.7 Safety Survey .......................................................................................................................... 250
4.8 Emergency Preparedness and Response Planning (EPRP) in Major
Accident Hazard Factories ................................................................................................... 250
Chapter 5 INITIATIVES TOWARDS SAFETY – GOI 252 – 255
5.1 Existing Set-up of Occupational Safety and Health
in the Workplace in India ..................................................................................................... 252
5.2 Government Bodies Dealing with OSH Regulations ........................................................ 252
5.3 National Level Autonomous Bodies/Organizations
Connected with Occupational Safety & Health ................................................................ 254
5.4 12th Five Year Plan Schemes in Respect to Safety ........................................................ 255
Chapter 6 SAFETY IN CONSTRUCTION 256 – 298
6.1 Safety Practices at Work Places ....................................................................................... 256
6.2 Indian Regulations .................................................................................................................. 257
6.3 Excavation Work ..................................................................................................................... 257
6.4 Scaffolds and Ladders .......................................................................................................... 262
6.5 Structural Work, Laying of Reinforcement & Concreting .............................................. 268
6.6 Road Work ............................................................................................................................... 271

12. 6.7 Cutting and Welding ............................................................................................................... 272
6.8 Working in Confined Space .................................................................................................. 277
6.9 Working at Heights ................................................................................................................ 278
6.10 Handling and Lifting Equipment ........................................................................................... 279
6.11 Vehicle Movement in Construction Work .......................................................................... 282
6.12 Demolition................................................................................................................................. 283
6.13 Radiography ............................................................................................................................. 286
6.14 Grit Shot/Slag Blasting/Spray Painting ............................................................................... 287
6.15 Tunneling .................................................................................................................................. 287
6.16 Safety Practices Adopted for Working with Construction Machinery ........................ 289
Chapter 7 MISCELLANEOUS 299 – 324
7.1 Occupational Health Problem .............................................................................................. 299
7.2 International Labour Organization (ILO) ............................................................................. 300
7.3 OSHA [Occupational Safety and Health Administration] ................................................ 300
7.4 Work on Tall Chimneys ......................................................................................................... 300
7.5 Boiler Safety ............................................................................................................................ 301
7.6 Nuclear Safety ......................................................................................................................... 303
7.7 Fire Safety ................................................................................................................................ 303
7.8 Dam Safety .............................................................................................................................. 304
7.9 Guidelines on Safety in Road Construction Zones .......................................................... 306
7.10 Safety in Building ..................................................................................................................... 311

13. 1.1 INTRODUCTION
1
Engineering drawing is a technique of creating graphical
representation that contains all necessary information such as
dimensions, specifications and notes using which an abstract concept
can be transformed into real world object. To realize such concept,
basic tools of construction of drawing has to be clearly understood
as to what standard has to be followed. There is an international
standard on code of practice for drawing which is followed and adopted
by Bureau of Indian Standard (BIS). In this chapter, we shall be
dealing with drawing instruments and accessories (i.e. drafting tools)
which is necessary for engineering drawing.
1.2 DRAWING SHEETS : [IS 10711 : 2001]
Consider an isosceles triangle ABC of unit length as shown below.
1 unitB A
1 unit
C
2 unit
45°
Now rotate BC anticlockwise so that BC becomes perpendicular to
AB as shown below.
2 unit
1 unitB A
1 unit
C
2 unit
45°
B A
C
1 unit
45°
Now taking AB as one side and BC as another side complete a
rectangle ABCD as shown below.
INSIDE
1.1 Introduction
1.2 Drawing Sheets
1.3 Drawing Board
1.4 Scales
1.5 Mini Drafter
1.6 T-Square
1.7 Set Square
1.8 Protractor
1.9 Compass
1.10 Dividers
1.11 Drawing Pencil
1.12 French Curves
1.13 Layout of a Drawing Sheet

14. 2 | ENGINEERING DRAWING GS AND ENGINEERING APTITUDE
IES MASTER Publication
C D
B A1 unit
45°
2 unit
C D
B A1 unit
A0 A0
DC
AB
x
y
2unit
There are two basic principles involved in arriving at
the sizes of A0 sheet
(i) x : y = 1: 2 , where, x, y  side
(ii) Surface area (xy) of A0 sheet is unity i.e., xy = 1
 x:y =
1
2

x
y
=
1
2
 y = x 2 ... (i)
Also, xy = 1  x·x 2 1 from (i)
 x2 =
1
2
 x = 
1 1
1.1892
 x = 0.841 m
 y = 0.841 2 = 1.189 m
Hence, value of x and y is given as
x = 0.841 m (or) 841 mm
y = 1.189 m (or) 1189 mm
Successive smaller sizes are obtained by halving
previous size sheets, with the above constant width
to length ratio i.e., (x : y = 1: 2 )
Example :
A1
A6
A0
A5
A3
A4
A2
2-D view
A0 1189×841
841
1189
A1841×594
A2 594×420
A3420×297
A4 297×210
3-D view
841
1189
A0 (841 mm × 1189 mm)
594
A1 (594 mm × 841 mm)
A2 (420 mm × 594 mm)
A3 (297 mm × 420 mm)
A4 (210 mm × 297 mm)
A5 (148 mm × 210 mm)
Note: The ISO ‘A’ series of sheet is based on
a constant width to length ratio of 1 : 2 .
Application
The relationship of 1: 2 is particularly important for
reduction onto microfilm, or reduction and enlargement
on photocopiers. All metric equipment including
microfilm cameras, microfilm printers, photocopiers and
even drawing pen sizes are designed around this ratio.
Note: (1) A2 size drawing sheet is preferred for
class use.
(2) Recommended size and its designation
of ISO ‘A’ series of sheet is given
below.
Table 1.1: Recommended size of drawing sheets
Drawing Sheet (IS 10711 : 2001)
Size (mm)
Length × Width
Designation
A0
A1
A2
A3
A4
1189 × 841
841 × 594
594 × 420
420 × 297
297 × 210
1.3 DRAWING BOARD : [IS 1444 : 1989]
It is generally made from soft wood such as white
pine, fir, oak, red cedar etc.
 To prevent warping, the board should be made of
narrow strips of wood joined together accurately.

15. 8 | ENGINEERING DRAWING GS AND ENGINEERING APTITUDE
IES MASTER Publication
Choose the most appropriate answer out of the given
alternatives :
1. A drafter helps in drawing
(a) parallel and perpendicular lines
(b) concentric circles
(c) smooth curves
(d) all the above
2. In the engineering system of paper sizes, which
of the following is “A2” size?
(a) 841 mm × 1189 mm
(b) 594 mm × 841 mm
(c) 420 mm × 594 mm
(d) 210 mm x 297 mm
3. Which of the following pencil leads is hardest?
(a) HB (b) H
(c) B (d) F
4. Which of the following purposes is not served
by dividers?
(a) Divide lines or curves into a number of
equal parts
(b) Transfer measurement from one part of
the drawing to another part
(c) Make full size, reduced size or enlarged
size drawing
(d) Step-off a series of equal distances on
the drawing
5. To draw smooth curves of any nature, the
draughting instrument used is
(a) mini-drafter (b) French curve
(c) templates (d) eraser shield
6. Parallel lines can be drawn with the help of
(a) mini-drafter
(b) T-square
(c) pair of set squares
(d) all of these
Questions
7. A typical layout of a drawing sheet does not
contain
(a) centering mark
(b) orientation mark
(c) trimming marks
(d) identification mark
8. Grid references on a drawing sheet provide
the following information:
(a) Location of details, additions, modifications,
revisions, etc. of drawing
(b) To facilitate the positioning of the drawing
when reproduced
(c) To facilitate brief record and initials of the
person responsible
(d) To facilitate trimming
9. “A” series of paper has length-to-width ratio of
approximately
(a) 3:2 (b) 3 :1
(c) 2 :1 (d) 5:3
10. The number of orientation marks generally
contained by a drawing sheet is
(a) one (b) two
(c) three (d) four
11. Extension arms are used with engineering
compasses to
(a) draw circles of larger diameter
(b) increase the gripping arm
(c) adjust distance between the legs
(d) increase accuracy
12. Which of the following statements are correct?
I. The length of A2 size drawing sheet is
equal to the width of A1 size drawing
sheet.
II. For technical drawing, harder grades of
pencils are preferred.
(a) only I (b) Only II
(c) Both (d) None